Dissolving Pulp PEERS October 2, 2011 - TAPPI ©Metso Rayon staple •Textile •Non-woven Viscose...

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Dissolving Pulp PEERS October 2, 2011 Paul Flickinger, General Sales Mgr. Lari Lammi, Sr. Sales and Technology Mgr. Bertil Ernerfeldt, Sr. Process Engineer

Transcript of Dissolving Pulp PEERS October 2, 2011 - TAPPI ©Metso Rayon staple •Textile •Non-woven Viscose...

Page 1: Dissolving Pulp PEERS October 2, 2011 - TAPPI ©Metso Rayon staple •Textile •Non-woven Viscose filament Rayon cord Industrial yarn Cellophane film Sponge products Sausage skin

Dissolving PulpPEERS

October 2, 2011

Paul Flickinger, General Sales Mgr.Lari Lammi, Sr. Sales and Technology Mgr.

Bertil Ernerfeldt, Sr. Process Engineer

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© Metso2

Rayon staple•Textile•Non-woven

Viscose filamentRayon cordIndustrial yarn Cellophane filmSponge productsSausage skin

Manufacturing process

Acetate towAcetate filamentAcetate mouldingsAcetate films

ZnCI2

Cupra*

Filter paperPhoto paperSpecialty papersGrinding / moulding powder

Wood

BindersGluesCMCDetergentsFoodPharmacyOil drilling mud

ExplosivesLacquersCelluloid

Dissolving pulp

*only from cotton linters, cupra is often classified as viscose fibre

CottonLinters

DissolvingPulp

Ethering Nitration Acetylation Xanthation Others

Ethers Nitrates Acetates Viscose

Vulcan fibre

H2SO4

Parchment

LatexArtificial leather

ResinsLaminating papers Impregnation papers

CuO/NH4OH

Source:

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Dissolving pulp demand by end product and region 2008

Note: Includes about 1 million tons cotton linters pulp.

End Product Region

Total market 4.2 million tons

Viscose63 %

Others3 %

Ethers14 %

Nitrates4 %

Acetate16 %

Total market 4.2 million tons

Asia61 %

North America11 %

Other regions3 %

Europe25 %

Source:

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© Metso

Dissolving pulp end use segments

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Source: WorldFibre Outlook, Pöyry

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1990 1995 2000 2005 2010 2015 2020 2025

Mill

ion

tons

Forecast

Rest of Asia

North AmericaWestern Europe

Japan

China

Rest of the World

The world demand for dissolving pulp is expected to grow from 4.1 million ADt/a in 2008 to 6.3 million ADt/a by 2025

Consumption of dissolving pulp by region –Medium scenario

Source:

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© Metso6 Date/Title/Author

Demands for dissolving pulp

• End user is a chemical company – high requests for the quality on the pulp

• Uniform product• High cellulose content

- Controlled, adjusted viscosity (DP)- Viscosity adjustment over the whole fiberline -> viscosity control stages

(Cooking,O2, H, P, Z)

• High purity- low, adjusted hemicellulose content- high brightness- low extractives content- low, adjusted metal ion profile- High brightness- Low brightness reversion

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Cooking

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© Metso8 Date/Title/Author

Basics of dissolving pulp cooking

• Removal and/or adjusting the amount of hemicelluloses

• Alkaline kraft pulping is not able to make enough hemicellulose removal

• There is a need for acidic conditions, which results in hydrolysis, bonds between sugars are broken down and dissolved

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Hydrolysis of hemicelluloses

• Prehydrolysis kraft cooking• Removal of hemicelluloses in the prehydrolysis stage• Removal of lignin in the cooking stage• Degree of hydrolysis and the purity of hemicelluloses relatively freely

adjustable• Possibility to use hydrolysate

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© Metso10 Date/Title/Author

Prehydrolysis stage

• Liquid or steam phase- Liquid phase, easy to adjust the pH- use of different acids, suplhur dioxide- conditions (time, temp, pH) easy to vary- Drawback: high volume of hydrolysate, no use (value) today

=> Only steam phase as a prehydrolysis stage is economically viable

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© Metso11 Date/Title/Author

Steam hydrolysis

• Direct LP and MP steam• 160-180 deg C• No additional chemicals, water• The effect comes from AUTOHYDROLYSIS

- the acids from wood release protons during steaming creating acidic conditions

• The effect of steam hydrolysis depends on- wood species- wood age- moisture content- Temperature

• Control of prehydrolysis by P-factor

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© Metso12 Date/Title/Author

/Sixta2006/E. urograndis

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© Metso13 Date/Title/Author

/Sixta2006/E. urograndis

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© Metso

Displacement Batch Cooking

19.11.2009 Lari Lammi

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© Metso

Metso

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© Metso16 Date/Title/Author

Metso Batch Dissolving CookingFeatures• Steam hydrolysis

- LP + MP steam for hydrolysis

• Strong alkali neutralization- WL pad

• Modern kraft cooking- HBL treatment - Cooking liquor addition- Uniform cooking- Gentle discharge- Low emissions

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© Metso

Typical operating figures for market pulp Metso Batch cooking

HARDWOOD SOFTWOODLP-steam consumption kg/adt 120-160 120-160MP-steam consumption kg/adt 400-500 400-550Power consumption kWh/adt 20-25 25-30Alkali consumption % EA as NaOH 17-19 20-22Yield % on wood 51-53 (@kappa 18) 47-48 (@kappa 30)

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Operating values dissolving pulp - examples

LP-Steam 400-500 kg/AdtMP-Steam 550-750 kg/AdtPrehydrolysis temperature 160-170 deg CPrehydrolysis time 20-60 minTotal sequence time 300-350 minCooking yield 35-39 % on woodPulp viscosity 600-1200 ml/gPentosan in pulp As low as 1.5% on pulp

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Factors affecting the values- Wood quality (species, moisture…)- Dissolving pulp quality (rayon, acetate…)

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Brown Stock Washing

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Brown stock washing and screening

• No major differences with kraft pulping• One important thing is that the knot/reject amount is lower than in

kraft pulping• Carry over to O2-stage could be higher than in normal kraft pulp –

however depending on the end-product viscosity level• Barrier washing – good control for conditions to O2-delignification

and bleaching -> stable and controllable pulp quality

Date Author Title20

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Oxygen delignification

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Oxygen delignification

• Single, two-stage or no O2

• Decision based on the following:- End-product viscosity – required viscosity loss in O2-stage- Softwood / hardwood- Only dissolving grade / also kraft pulp

• Pulp viscosity can be controlled by temperature and alkali charge in the oxygen stage

Date Author Title22

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Bleaching

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Bleaching

• There should be a possibility to control the viscosity in 1-2 stages (Oxygen delignification/bleaching) depending on the request for end-product quality

• Normally a sequence for high brightness is needed• Normally a sequence for low brightness reversion is needed• Demineralized wash water needs normally to be used in the last

washing after bleaching

Date Author Title24

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© Metso

Possible bleaching sequences

• In the past:- C-E-H-D- C/D-EO-H-D

• Future- D-EOP-D-D- D-EOP-D-P- O-D-EOP-D-D- O-D-EOP-D-P- O-A-Zq-P

Date Author Title25

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Fiberline for Dissolving Pulp - ECF bleaching

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Fiberline for Dissolving Pulp - TCF bleaching

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Bahia Pulp experiences• Metso Cooking and Fiberline gives good opportunities to produce

different qualities of dissolving pulp• Knowledge comes only with hands on practice

- Different pulp behavior in the digester than with normal kraft pulp- How to control the viscosity in the whole fiberline

• Lot of issues which may be “small” during design phase but have a significant influence on the operation if not correct

• Very much different approach to quality than producing market paper pulp

• More requirements for preventive maintenance • Metso has a running reference and hands on practice of designing

and producing dissolving pulp – with excellent quality (according to end-user requirement)

Date Author Title28

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© Metso33 Date/Title/Author

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© Metso34 Date/Title/Author

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INTERNAL

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© MetsoDate/Title/Author

Typical DP Fiberline

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Summary

• End-product specifications determine the design• Cooking with steam prehydrolysis• Washing in brown stock with presses in order to control the carry-

over to O2/bleaching thus control the viscosity drop• Barrier washing in bleaching to get sharp controllable stages –

control the viscosity drop• ECF/TCF solutions possible – Ozone one alternative for viscosity

control • Decisions regarding kraft/dissolving pulp ratios and raw material

have an impact on the design

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